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Hey guys I bought a helmet from the member Asok? If memory hasn't failed me.

I did the visor cut out and got the rough sanding and everything finished but I lost my job for a few months and the project got put on hold. I came back to my helmet after several weeks to find it is completely misshaped. Not a subtle misshape either. I'm talking the cheek pieces are touching the top of the brow making the eye visor only a few mm open. Not sure if that makes sense.

I need to buy the visor from Asok so I can finish the helmet but how will I get the shape back? What would you recommend? If I can't fix this helmet I will be so bummed I don't think I will bother to finish it.

Your problem started when you cut out the T-visor area and leaved it that way for weeks with no support for the mandibles and your helmet collapsed in the weakest parts. For future reference, it's always recommended to cut out a piece of sintra in a T-visor shape and tape it inside the mandible area to increase the stability of your helmet. If I presume correctly, then the mandibles are also leaning inward and almost touch the brow so it is possible to fix it (if there are no cracks) by heating gently the mandible base area (near the ears) with a heat gun and then holding the mandible in the right position until it cools down. You are done if the distance between the brow and the end of the mandible is at 20-22mm and the distance between the mandible ends is around 44-48mm. I recommend to post some images with the warped area (before you do any changes) to get better advice on how to fix it.

what I do is cut the visor with painters tape on it to size mount it leave the tape on while I paint then remove when Im through it works as a mask and shapeholder....you also want to cover the backside with tape if doing this for overspray

Thanks for the replies guys. I have been busy and hadn't had much time to reply.

I was able to get the shape back with the cheeks but the eye gap is a little thinner than I had it originally. Not the hardest part to fix. The hard part is getting the helmet round again. I'm thinking of putting it on something round like a small soccer ball or etc and heating it with a heat gun and then using tape to help it hold its shape to the shape of the ball inside. The helmet is strong and I can apply a lot of pressure on the sides to get it rounder but it's hard to keep it pushed in with anything. I will try the heat, ball and tape trick probably. I still need to buy the visor.

Unfortunately this happens to people all the time. A Fett helmet has VERY little structural integrity once the visor area is cut out. I always keep my helmets on stands. Even when I display them at cons, I bring stands with me. That way heat and gravity don't do that to me!